Well, if Bill doesn't want it mate, I'll sort something out with you...

Just ordered a few odds and sods from Audi too. They want £5.16 plus VAT EACH for the turbo to manifold WASHERS! The bloody bolts are cheaper than the washers! I nearly fell off my chair!!

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cool dude!!

haha weird how some small bits from stealers can cost a fortune and bigger things can be relatively cheap, guess its how they make their money, well extra money on top of the millions they already rake in lol

remember someone off toyota forum (when i had t sport) wanting a new dipstick, went to stealers, you wouldnt even guess the price £85 + vat so not far off a tun!!

You are a star Bill, appreciated. If they are, let me know and I'll drop in and grab them tonight.

Hopefully the shells will be here today as well. Picking up the head later. I went to get my £115 piece of metal from Audi this morning and dropped it off.

The head looks spanking new, so impressed with the work done for the money....

Jonny, yeah, hoping she'll be ready for her running in at the weekend. I've ordered a sticker for the back window 'Running in - pass while you can'. I got the idea from a Cossie I saw on the motorway once....

------------------------------------------------------------------------------------------"Marriage is like a coffin and each kid is another nail." Homer Simpson​

Jonny, yeah, hoping she'll be ready for her running in at the weekend. I've ordered a sticker for the back window 'Running in - pass while you can'. I got the idea from a Cossie I saw on the motorway once....

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Was it a White Sierra Cossie by any chance? Many years back when I was filling up at Shell, there's was a White Sierra with the same sticker on his rear window, and I laughed and asked him why he was running it in? He said he just spent £4k rebuilding the engine after he blew it up.

Was it a White Sierra Cossie by any chance? Many years back when I was filling up at Shell, there's was a White Sierra with the same sticker on his rear window, and I laughed and asked him why he was running it in? He said he just spent £4k rebuilding the engine after he blew it up.

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It was as it happens, I saw him pottering down the M5. How weird, this was many years ago as well. Maybe the same one - seems too close a match to be coincidence.

Absolutely spanking it was, looked brand new.

------------------------------------------------------------------------------------------"Marriage is like a coffin and each kid is another nail." Homer Simpson​

New lump totally stripped, everything swapped over. Happy with the clutch, looks really good as does the flywheel.

New engine has been stood for a while. Oil was NASTY! Taken all parts that I can swap over, but after 1000 miles I thoroughly intend to flush the engine and change the oil to get rid of any lasting 'old oil' nastiness.

New con rods, and shells arrived (Thanks again Bill - legend ). Pistons went on the rods fine, and then into the block. Gave one of the oil squirters a nudge, but a gentle push with a flat head screwie put her back where she belonged! What a pain though!

Head is back also - looking immaculate. SAI blanking plate from Forge fitted as well.

Ready to refit the block tomorrow...

Photos:

Engines during the parts swap

AGU head *cough* for sale *cough*

Head back from A&M. Top job they've done for £150, 100% impressed.

New block, water pump fitted, no pistons though....

New IE rods. Out with the old, in with the new.

Ready to go into the block....

Lost the will to take photos after this.

Tune in for tomorrow's exciting instalment.... lol.

------------------------------------------------------------------------------------------"Marriage is like a coffin and each kid is another nail." Homer Simpson​

No damage or nicks, so they should be fine as long as the bores are in good condition, even in another bore. A NEW bore would of required new rings. Honing on the current bore will allow the rings to seat properly (hopefully) and it will seal right for power and oil control.

I would of replaced them if they were worn. They'll soon take to another bore anyway.

I can't see there being any issues, well, lets hope not! lol.

Last edited: Feb 16, 2010

------------------------------------------------------------------------------------------"Marriage is like a coffin and each kid is another nail." Homer Simpson​

What a NIGHTMARE. Got it up to the right level at about 6 PM ready for it to just 'slot' on.... Then spent 4 hours kicking it and moving it about trying to get it in. Made hell of a mess of the inside of the bell housing of the gearbox (flywheel teeth grinding) so there was filings all over the joint!

Anyways, after 4 hours of fiddling about trying to rough it in we decided to stop (not having ANY joy) and go back to basics. Pulled block back out, and dropped to the deck. Checked the clutch plate alignment etc etc, all fine. Cleaned the filings out of the bell housing with the Dyson (whoops).

Block back up, into position - and on first time. I couldn't bloody believe it

Bolt the box up. Happy because it's in. Happiness that was short lived.... lol.

Tried turning engine over. Not a sausage, she wouldn't budge. Check it wasn't in gear, all the obvious things. Nope. Check the metal plate behind the flywheel was visible and hadn't got jammed in the teeth of the flywheel on the way in. Nope. As we were reigning ourselves to taking the block back out I has a brainwave. Got in the car and dumped the clutch. YAY. Engine turns over.

Clutch must of not been located quite correctly, as now the clutch pedal is good, you can hear the thrust bearing pushing on the clutch. And the engine turns over al the time now, nice and smoothly. What a relief!!

So, all we managed to do last night was get the block in the car and bolted to the box. What a let down!

Only 2 pics from last night as was feeling somewhat lazy after a 10 hour day at work, then another 7 on the car (2.30 AM bedtime )

Block totally assembled.

Me being a penis. . Not often you get to take a photo like that though!!

More tonight....

------------------------------------------------------------------------------------------"Marriage is like a coffin and each kid is another nail." Homer Simpson​

Totally agree, biggest mistake that can be made I think. Not in any huge rush to get it done, got Friday off so tonight, tomorrow night and all day Friday should see me good. And then have the weekend as overflow anyway.

Rush = make stupid mistakes.

------------------------------------------------------------------------------------------"Marriage is like a coffin and each kid is another nail." Homer Simpson​

<tuffty/>Badger 5 Edition...Its all about the flow...Staff MemberModeratorAudi S3

Oh, and on an unrelated note, I HATE that turbo support bracket. Every single thing I have done, it has been in the bloody way! Grrrrrrrr

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Isn't it!!!! you can't even remove the damn thing without removing the trnasfer box... I ended up cutting it off as close as I could with a disc cutter in the end and sorta cut through the oil level sensor wire

No such luck for me mate, I need to use mine again, where as you didn't! I cannot believe it has been designed so badly, the heads of the bolts for it must be 4mm at most from the transfer box. That would actually be impossible to replace if needed. Hex tops at least you could of got a spanner on them!

Anyway, Jonny discovered whilst we were taking the block out (as the TSB kept fouling on that bit that sticks out on the transfer box), that rather than removing the TSB - we could just unbolt the bit that sticks out from the transfer box - it actually just unbolts and comes off.

Was sooooo happy when we found that - block came straight out! It would of been next to impossible otherwise!

Last edited: Feb 17, 2010

------------------------------------------------------------------------------------------"Marriage is like a coffin and each kid is another nail." Homer Simpson​

Started with an engine which wasn't even hanging on it's mounts, and ended up with this:

Needless to say were were pleased! lol.

Sump is all back on and bolted. All the ancillaries are back on. It's holding water fine which is good. (even though initially I filled the header tank up whilst the pipe to the side of the head was off..... whoops). Loom is all reconnected.

Left to do is the following:

Inlet Manifold - fit and connect. Turbo Mani gasket and bolt down turbo. Couple of gearbox-engine bolts at the back. Time up & fit new belt. Refit bottom pulley, aux belt & tensioner. A few other bits and bobs like the MAF and charge pipe assembly.

Got tomorrow off - so am going to have a break from it tonight. Been at it all night after work for 3 days running until 2 AM every night so I am shafted! (although will probably do a few bits and bobs!) and finish up (hopefully tomorrow during the day. It will be nice to work on it in the daylight!

------------------------------------------------------------------------------------------"Marriage is like a coffin and each kid is another nail." Homer Simpson​

I was so nervous at first start time..... hands were actually shaking!! lol.

Anyway, fired up first turn of the key (after a few turns to get some fuel through).

Anyway, come across another issue now.... oil pump on the AGU block is shot. Keep getting dash oil pressure warnings and there is no oil in the head - it's all static in the sump. In hindsight we should of changed it for the APY's but there we go. What a pain though. Means the sump is going to have to come back off after only just being sealed.

Arse.

Hopefully take it out for a test run tomorrow night, once all the rest of the kit has been refitted....

So happy it works though!

------------------------------------------------------------------------------------------"Marriage is like a coffin and each kid is another nail." Homer Simpson​

I was so nervous at first start time..... hands were actually shaking!! lol.

Anyway, fired up first turn of the key (after a few turns to get some fuel through).

Anyway, come across another issue now.... oil pump on the AGU block is shot. Keep getting dash oil pressure warnings and there is no oil in the head - it's all static in the sump. In hindsight we should of changed it for the APY's but there we go. What a pain though. Means the sump is going to have to come back off after only just being sealed.

Arse.

Hopefully take it out for a test run tomorrow night, once all the rest of the kit has been refitted....

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